Flexible-round stand-up pouch

ABSTRACT

A thin, heat-sealable packaging material is formed into an open cylindrical pouch having a recessed, round or oval base, similar to the base on paper cups. After filling, the opening of the pouch can be sealed to itself with heat and pressure using known techniques. The innovative design utilizes known technologies to form a stand-up heat-sealable pouch.

BACKGROUND OF THE INVENTION

[0001] 1. Technical Field

[0002] The present invention relates to product packaging and moreparticularly to providing packaging of a product, such as a snack food,in a stand-up pouch.

[0003] 2. Description of Related Art

[0004] Pouch Packaging

[0005] Many snack foods, like chips, pretzels, etc., are packaged inpouches formed of very thin packaging films. This method of packaging isbest described in conjunction with a description of the vertical form,fill, and seal packaging machine that makes and fills the pouches, seendiagrammatically in FIG. 1. Packaging film 110 is taken from a roll 112of film and passed through tensioners 114 that keep it taut. The filmthen passes over a former 116, which directs the firm into a verticaltube around a product delivery cylinder 118. As the tube is pulleddownward by drive belts 120, the vertical tube of film is sealed alongits length by a vertical sealer 122, forming a back seal 124. Themachine then applies a pair of heat-sealing jaws 126 against the tube toform a transverse seal 128. This transverse seal 128 acts as the topseal on the bag 130 below the sealing jaws 126 and the bottom seal onthe bag 132 being filled and formed above the jaws 126. After thetransverse seal 128 has been formed, a cut is made across the sealedarea to separate the finished bag 130 below the seal 128 from thepartially completed bag 132 above the seal. The film tube is then pusheddownward to draw out another package length. Before the sealing jawsform each transverse seal, the product to be packaged is dropped throughthe product delivery cylinder 118 and is held within the tube above thetransverse seal 128.

[0006] The material used in this type packaging is typically a packagingfilm, such as polypropylene, polyester, paper, polyolefin extrusions,adhesive laminates, and other such materials, or a layered combinationof the above. For many food products, where flavor retention isimportant, a metalized layer will form the innermost layer.

[0007] One problem with this type of packaging is that the pouches willnot stand up by themselves, but tend to fall over on their sides unlessthey are supported. This can create difficulties in storage, both forthe seller and the consumer. Despite this drawback, this packagingmethod has remained popular, as it is a very cost effective means ofpackaging.

[0008] Paper Cups

[0009] In a different area, paper cups and paper containers have beenknown for many years, although innovations to the process continue tothe present. An overview of one method of forming a paper cup will nowbe discussed, but further details are available in many patents, such asU.S. Pat. Nos. 4,452,596 and 6,264,100, which are both herebyincorporated by reference. FIG. 2 shows a wall blank 210 and a circularbase blank 212 that have been cut out of paperboard to use in forming abasic paper cup. FIG. 3A shows a first step during manufacture, wherethe wall blank 210 is wound around a tapering mandrel 380, then the endsare secured with an adhesive to form the tapering tube 310 with seam311. In a separate step, a piston forces the base blank 212 through anopening having a smaller diameter than the blank itself, forming a rimor short, cylindrical edge 314 that projects at a right angle to thecircular base, as seen in FIG. 3B. The formed base 312 is then insertedinto the bottom of the now-sealed tube 310. As seen in FIG. 3C, the rimof the base section 312 can be positioned slightly above the lower edge316 of the wall section 310. Finally, the lower edge 316 of the wallsection is crimped over the rim 314 of the base section 312 and sealedwith an adhesive to form the reinforced rim 318, as seen in FIG. 3D.Most cups will have the top edge 320 of the cup rolled in an early stepto form a thicker lip for the cup, although that step is not shown here.This basic manufacturing process can be modified, of course, to provideadditional improvements, such as a handle or a sealant/coating for thepaperboard to prevent wetting of the cup by its contents, and a lid canbe made separately if it is desired, such as when the cup will be usedto transport hot soup or a similar liquid. These containers, unlike thepouch containers, have round bottoms, which give them a stable base onwhich they can sit. However, to ensure that the container will notcollapse on itself and spill its contents, these containers aregenerally made of paperboard, and often they are treated with coatingsor sealants to make them impervious to liquids. The result is acontainer that is heavier and more expensive than those used to packagesnack foods.

[0010] It would be desirable to find a method of packaging a product,such as a snack food, in an inexpensive container that would stand upand that could be formed out of less expensive, lightweight packagingmaterials.

SUMMARY OF THE INVENTION

[0011] In the present invention, a package is formed having a rounded,recessed base, similar to the base on paper cups. The recessed base canbe round or generally oval, while the sidewalls are preferably straight,rather than tapering, as do the sides of a paper cup. In the place ofpaperboard, thin packaging polymers are utilized, such as thosepackaging materials that are currently used in forming pouches for snackfoods. The formed packages are filled with a product and opposite edgesof the open walls are brought into close proximity for heat sealing.

[0012] A major advantage of the innovative package is that the round oroval base allows the package to be stored upright on a shelf withoutfurther support, maintaining its upright position even when filled withlight-weight products. Unlike prior packages with rounded bases, it isnot necessary to use a heavy paperboard to hold the shape, so the costis reduced. The materials for the package have been used for years, sothey are well understood and well suited to food products. The size ofthe packages can be easily modified, so that, for example, a snackpackage can be sized to fit into the cup holders in an automobile. Thispouch can be used for eating out of the container; for example, if usedfor packaged cereal, milk can be added directly to the pouch. Likewise,chips could be packaged in this pouch, with a cheese topping to be addedbefore eating. Finally, this pouch has the potential for storing liquidproducts and can also be used in vending machines.

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] The novel features believed characteristic of the invention areset forth in the appended claims. The invention itself, however, as wellas a preferred mode of use, further objectives and advantages thereof,will be best understood by reference to the following detaileddescription of illustrative embodiments when read in conjunction withthe accompanying drawings, wherein:

[0014]FIG. 1 is a diagrammatic view of a form, fill, and seal machine,known in the prior art.

[0015]FIG. 2 shows blanks for the sidewall and base of a paper cup.

[0016]FIG. 3A shows the formed walls of a paper cup, while FIG. 3B showsthe formed base of the cup. FIG. 3C shows the base and sides as they arefirst fitted together and FIG. 3D shows the base of the container afterthe two pieces have been sealed together.

[0017]FIG. 4A shows the blanks used to form an embodiment of thedisclosed packaging, FIGS. 4B and 4C show the formed base and the formedsidewalls respectively of the package. FIGS. 4D and 4E show respectivelythe sidewalls and base of the package sealed together and the filledpackage after sealing.

[0018] FIGS. 5A-D show the disclosed package at various stages as it isbeing filled with product and sealed.

DETAILED DESCRIPTION

[0019] The invention will now be described with reference to FIGS. 4-5,which depict an exemplary embodiment.

[0020]FIG. 4A shows blanks 410, 412 for an embodiment of the innovativepackage. The wall blank 410 is preferably rectangular in shape and has alength slightly greater than the desired finished height and a widthappropriate to the base to which it will attach. The base blank 412 isround or generally oval in shape to accommodate the processing methodand to form a stable base for the package. The packaging material fromwhich the blanks are cut can be any of the popular packaging films nowused in pouch manufacture. Examples are polypropylene, polyester, paper,polyolefin extrusions, adhesive laminates, and other such materials, orlayered combinations of the above. Where flavor retention is important,a metalized layer will form the innermost layer. In the presentlypreferred embodiment, one of the following laminations is used: 1) ametallic oriented polypropylene layer on the inside having an exposedsealant layer that is heat activated, followed by a polyethylene layer,an ink layer, and an outer oriented polypropylene layer; 2) a metallicpolyethylene terephthalate (PET) inner layer having an exposed sealantlayer, followed by a polyethylene layer, an ink layer, and an orientedpolypropylene layer on the outside; and 3) a metallic orientedpolypropylene inner layer with an adhesive, followed by a polyethylenelayer, a paper layer and ink.

[0021] The two blanks 410, 412 are shaped in much the same manner as inpaper cup manufacture. FIG. 4B shows the base blank 412′ after rim 414has been formed on this piece. In this figure, the upper and outersurfaces of the base include a sealant layer. In FIG. 4C, the sidewallblank 410′ has been formed into a cylindrical shape and sealed at backseal 414. The back seal 414 can be formed as either an overlap seal or afin seal and will be sealed by a pair of heat sealing jaws.

[0022]FIG. 4D shows an embodiment of the disclosed package 400, afterthe sides and base have been joined. In this embodiment, the lower edgeof rim 414 of base 412′ has been positioned to coincide with the loweredge of sidewall 410′, and the two pieces 410′, 412′ have been heatsealed to each other. In an alternate embodiment, rim 414 of base 412′is positioned slightly above the lower edge of sidewall 410′, then thelower edge of sidewall 410′ is folded over so that rim 414 is enclosedbetween two layers of sidewall 410′. This embodiment would give asomewhat sturdier rim to the base. In FIG. 4E, the package 400′ has beenfilled with a product and a top seal 420 formed using heat sealing by apair of opposed jaws. Dwell times for the formation of the heat seals onthe base of the package would generally be in the 0.5-1.0 second range,while the back and top seals would typically have a dwell time of0.1-0.5 seconds.

[0023] FIGS. 5A-D show a diagram of one embodiment of the innovativepackages being filled and sealed. In FIG. 5A, empty package 500 has beenformed and is ready to be filled. Since the package can maintain anupright position, no support is necessary as it is being filled andsealed. FIG. 5B shows the package as it is being filled with a product,in this example, tortilla chips, one of the many products suitable forthis type of packaging. In FIG. 5C, the product is in the package 500,and sealing jaws 520 are preparing to bring the sides of the package 500together so that they can be heat sealed. In this diagram, only the jawfacings themselves are shown, but one of ordinary skill in the art wouldrecognize the machinery this represents. In FIG. 5D, the final package500′ has top seal 510 and is ready for boxing and shipping to theretailer.

[0024] In the presently preferred embodiment, containers are madeoutside of the packaging plant and shipped, preferably in a nestedformation, for filling and sealing in the plant. Alternatively, theequipment to make the bags could replace an existing packaging machine,so that the newly manufactured bags could immediately be filled withproduct and sealed.

[0025] The disclosed packaging is a novel combination of twotechnologies—the technology of making paperboard into a cup or containerand the technology of packaging snack foods into thin-walled,inexpensive pouches. This novel package provides a simple, economicalcontainer that stands upright, yet is sturdy enough to use in storingmany different lightweight products, including foods.

[0026] While the invention has been particularly shown and describedwith reference to a preferred embodiment, it will be understood by thoseskilled in the art that various changes in form and detail may be madetherein without departing from the spirit and scope of the invention.

What is claimed is:
 1. A package containing a product, said packagecomprising: a sidewall formed from a flexible packaging material that isheat sealable to itself; and a substantially round or oval shaped baseformed from said flexible packaging material, said base being attachedto a first edge of said sidewall; wherein said sidewall is sealed toitself at a first seal that is substantially perpendicular to the planeof the base and at a second seal that is remote from said base andsubstantially perpendicular to said first seal.
 2. The package of claim1, wherein said base is recessed from a lower edge of said sidewall. 3.The package of claim 1, wherein a portion of said base is enclosedbetween two layers of said flexible packaging material that form saidsidewall.
 4. The package of claim 1, wherein said flexible packagingmaterial comprises polypropylene, polyester, paper, polyolefinextrusions, adhesive laminates, metalized layers or a layeredcombination of the above.
 5. A method of packaging a product, saidmethod comprising the steps of: providing a pouch having a substantiallyround or oval base and sidewalls, wherein a rim of said base is sealedto said sidewalls; filling said pouch with the product; after saidfilling step, sealing opposite sides of said sidewalls together usingheat and pressure.
 6. A package, comprising: a substantially round oroval base, wherein said base is formed from a non-paperboard packagingmaterial that is heat sealable to itself; and sidewalls formed from saidnon-paperboard packaging material; wherein said base and said sidewallsare heat sealed to each other along a rim of said base.
 7. The pouch ofclaim 6, wherein said flexible packaging material comprisespolypropylene, polyethylene, polyester, paper, polyolefin extrusions,adhesive laminates, or a layered combination of the above.
 8. The pouchof claim 6, wherein a portion of said base is enclosed between first andsecond layers of said sidewalls.
 9. The pouch of claim 6, wherein saidsidewalls meet said base at a substantially normal angle.
 10. A method,comprising the steps of: cutting a base piece and a sidewall piece froma non-paperboard packaging material that is heat sealable to itself;forming and scaling said sidewall piece into a tube; forming a rim onsaid base piece that projects substantially 90 degrees from theremainder of said base piece; and sealing said rim of said base piece toan end of said tube to form an open package.
 11. The method of claim 10,wherein said step of forming a rim comprises forcing said base piecethrough an opening that is small in diameter than said base piece. 12.The method of claim 10, wherein said cutting step cuts a base piecehaving a circular or oval shape.
 13. The method of claim 10, furthercomprising the steps of: filling said open package with a product; andsealing an opening of said open package using heat and pressure.
 14. Abag made according to the method of claim 10.